Process for the production of an ingot

Abstract

In a process and apparatus for forming an ingot having a length at least twice as great as its characteristic sectional dimension, droplets of molten metal are sprayed onto a catching surface of a dummy bar which is rotated about its axis and moved in a removal direction along its axis. Layers of spray built up on the catching surface form an ingot. Boundary surfaces may be provided for shaping one of the surfaces of the formed ingot. In the case of a hollow ingot, the boundary surfaces are in the form of a partially cylindrical mandrel extending axially into a hollow dummy bar.

What is claimed as new and desired to be secured by Letters Patent of the United States is: 
     
       1. A process for forming an ingot having a length at least twice as great as a characteristic sectional dimension thereof, comprising the steps of: spraying droplets of molten metal from spray means and in a first direction;   positioning an element having a catching surface in the path of said sprayed droplets;   providing a boundary surface adjacent said catching surface;   rotating said catching surface about an axis angularly spaced from said first direction by between 90° and 180°, whereby layers of said sprayed droplets are evenly applied to said catching surface to form a continuous agglomerate and, when said catching surface is covered by said agglomerate, said layers are evenly applied to a catching surface of said agglomerate; and   continuously moving said agglomerate along said axis as said layers are applied and at a rate such that said catching surface remains at a constant distance from said spray means, whereby a longitudinal ingot surface is formed by said agglomerate layers.   
     
     
       2. The process of claim 1 including the step of moving said catching surface in an oscillating motion transverse to said first direction, whereby said layers are evenly applied over the entirety of said catching surface. 
     
     
       3. The process of claim 1 including the step of positioning said boundary surface to extend in the direction of said axis. 
     
     
       4. The process of claim 1 wherein for the production of an ingot having a circular section, said boundary surface is not rotated. 
     
     
       5. The process of claim 1 wherein for the production of a hollow ingot said boundary surface is a cylindrical portion of a mandrel inside said hollow ingot. 
     
     
       6. The process of claim 5 wherein said mandrel rotates about said axis. 
     
     
       7. The process of claim 6 wherein said mandrel is slightly conically shaped. 
     
     
       8. The process of claim 5 wherein said mandrel is not rotated. 
     
     
       9. The process of claim 3 wherein said boundary surface is positioned such that a portion of said sprayed droplets strikes said boundary surface. 
     
     
       10. The process of claim 5 wherein said mandrel is positioned such that a portion of said sprayed droplets strikes said boundary surface. 
     
     
       11. The process of claim 3 wherein said boundary surface is oscillated along said axis during said spraying step. 
     
     
       12. The process of claim 3 wherein said boundary surface is oscillated around said axis during said spraying step. 
     
     
       13. The process of claim 3 including the step of cooling said boundary surface. 
     
     
       14. The process of claim 1 wherein for the production of a solid ingot said boundary surface is outside of said ingot.